Multicolored yarns made from blend of different denier fibers

ABSTRACT

Multicolored yarns comprising a blend of (a) first fibers of first denier and color and (b) second fibers of second denier and color, said second denier being higher than said first denier, said second color being different from said first color, the blend proportions being such that said second fibers do not exceed in quantity the weight of said first fibers in said blend, and the two deniers having a mathematical relationship, one to the other.

United States Patent Inventors l-lldeto Seklguchl Saidaiji; TomohideMatsumoto, Saidaiji; Masanobu Hoten, Saida iji; Hideo Kawasaki,Nishinomiya, all of, Japan Appl. No. 842,019

Filed July 15, 1969 Patented Sept. 14, 1971 Assignee American CyanamidCompany Stamford, Conn.

MULTICOLORED YARNS MADE FROM BLEND OF DIFFERENT DENIER FIBERS 10 Claims,No Drawings U.S. Cl 57/140 BY, 28/72.17, 57/153 Int. Cl D02g 1/18, D0233/02, D02g 3/24 Fieldoi Search ..57/l53, 140

R, 140 BY, 157 R, 157 MS; 28/72.17

Primary Examiner.lohn Petrakes Altorney-William J. Van Loo ABSTRACT:Multicolored yarns comprising a blend of (a) first fibers of firstdenier and color and (b) second fibers of second denier and color, saidsecond denier being higher than said first denier, said second colorbeing different from said first color, the blend proportions being suchthat said second fibers do not exceed in quantity the weight of saidfirst fibers in said blend, and the two deniers having a mathematicalrelationship, one to the other.

MULTICOLORED YARNS MADE FROM BLEND OF DIFFERENT DENIER FIBERS BACKGROUNDOF THE INVENTION This invention is in the field of textiles and, moreparticularly, in the field of fibers and yarns.

Prior to the present invention various methods have been proposed forthe production multicolored textile products. in one method, forexample, a quantity of fiber is divided into portions, each portion isdyed with a different color, and the dyed portions are blended and spuninto a multicolored yarn which, after fabrication such as by weaving,knitting, etc.,

yields a multicolored product. Another method consists of the steps ofblending dyed fiber with similar undyed fiber, spinning the resultingblend into yarn, and subsequently dyeing the undyed fiber, prior to orsubsequent to fabrication, with a dye of color dissimilar from thatemployed with the for 10.0221 215.0 i

0.87 log 11 0.20 109D f0.57 log d+ 0.74.

In order that the proper ratio of deniers can be readily understood,various values of denier d of fiber (a), as discussed hereinabove, arearbitrarily selected and the corresponding values of denier D for fiber(b) are calculated according to formulas l and ll, given above. Thecalculated values are given below in table 1.

previously dyed fiber, thus producing a multicolored product.

In still another method, fibers with dissimilar dyeing properties areblended, the blend is spun into a yarn, and the yarn, or fabricatedarticle obtained therefrom, is subsequently dyed taking advantage of thedissimilar dyeing properties to yield a multicolored product.

The multicolored products obtained by the conventional methods are farfrom satisfactory with respect to the definition or contrast of thevarious colors present. Although two or, more colors are present in theresulting products, visual perception of the distinct colors is notpossible except upon very close examination. ln most instances theso-called multicolored products appear to be of a single predominantcolor containing some shade variations and the individual colors areblurred. In some instances, the color visualized would appear to be thatresulting from blending of the dyes prior to dyeing rather than fromblending of fibers of different colors. This lack of definition orcontrast of the individual colors present gives rise to a situationwhere products that in fact are multicolored do not have in effect theappearance of multicolored products. The present invention providesyarns that are multicolored both in fact and in effect.

SUMMARY, INCLUDING PREFERRED EMBODIMENTS ln accordance with the presentinvention, there is provided. multicolored yarns of novel color effects,said yarn comprising a blend of from about 95 percent to about 50percent by weight, of said blend, of a first fiber of one color, saidfirst fiber having a denier d, and, correspondingly, from about percentto about 50, by weight, of said blend, of a second fiber of a colordifferent from that of said first fiber, said second f ber having adenier I), said denier d being lower than said denier D and ranging from1.5. to 15.0, with said second denier l) satisfying the relationship:

(I for l.5d3.0 1.0.87 log d +0.20log DL39 logd+0.35, and

(2) for 302112150 0.87 logd+0.200.57 logd+0.74.

Thus, for the realization of multicolored yarns of novel color effects,it is not only necessary that the fibers of the blend be of differentdeniers and proportions, but it is also necessary that a specific ratioof deniers be satisfied. When the deniers are outside the specificratios specified, the novel color effects are not obtained. When thefiber, proportions are not within the range specified, either novelcolor effects are not achieved or spinability of the yarn is adverselyaffected.

While the proportions of blend fibers and the denier rela-. tionshipsthereof given above encompass the multicolored}, yarns of novel coloreffects of the present invention, even more striking novel color effectsare obtained when the proportions of (a) as defined above, are limitedto from about 95 percent to 85 percent by weight, of said blend, theproportions of (b) as defined above, are limited to from about 5 percentto about percent, by weight, of said blend, and the relationshipsatisfied by said denier D is:

TABLE! Calculated Values of D For Selected Values of d Calculated Valuesfor Denier D i Selected Minimum Maximum Preferred 0 Denierd Value ValueValue Calculated from fgrmu la l, V g 2 Calculated from formula II.

3 Obtained equally from either portion of fonnula l. 3 5 iQbteiq q llvfreq! s hqtnarti ns iarmt bL Although the particular factor responsiblefor the novel icolor effects observed is not known for certain, it isfelt that ythe novel color effects result from the particular yarnstruclture, i.e. the presence of fibers of different denier in specificproportions resulting in the fiber of higher denier tending to emerge ofthe yarn surface.

, The novel color effects obtainable by the present invention I may befurther enhanced when the fiber of higher denier has a lower shrinkageand a lower crimp number than the fiber of ;lower denier. Similarly,improved results are obtained when 5 the fiber of lower denier is acomposite fiber and the fiber of higher denier is a monocomponent fiberof relatively low crimp number. Especially beneficial results areobtained when :the fiber of lower denier is an acrylic fiber which hashigh shrinkage and was drafted by means of a Turbo-Stapler i (usually ata draft of 1.15 to 1.50), the fiber of higher denier has low shrinkage,and the yarn is subsequently dyed in two colors. in such instance at theelevated dyeing temperature the yarn of lower denier undergoes greatershrinkage than the fiber of higher denier with the result that theformer fiber tends to collect in the core of the yarn and the latterfiber tends to emergeto the yarn surface. The result is that the eflfectof the spinning operation due to denier variations are 5 reinforced toprovide novel color effects of greater definition and contrast.

The novel color effects of the yarn of the present invention are notlimited. to two-color dyeings but are also pronounced in productsconstructed of multicolored yarns of the present 'invention. Thesemulticolored yarns are readily achieved by T substituting for partof afiber of one color and denier an equal part of a similar fiber ofdifferent color but same denier, by

substituting for part of the fiber of one denier an equal part of afiber of different dyeing characteristics but same denier, or byemploying, where appropriate, a composite fiber whose components havedifferent dyeing characteristics, for exampie.

The fibers that may be employed in spinning yarns of the presentinvention generally include synthetic fibers made from high polymerssuch as polyamide, polyester, polyacrylonitrile,

- etc. Particularly superior yarns, featuring sharp color contrasts, areobtained when fibers of polyacrylonitrile or its copolymers, which areexcellent in dyeability, are employed.

In selecting fibers defined as (a) and (b), hereinabove, it is I notnecessary that fibers (a) and (b) be of the same type. Thus, it ispossible to use as fiber (a), for example, acrylic fibers dyeable withacid dye such as fibers of acrylonitrile copolymer containing such basiccomonomers as vinyl pyridine, N,N-dimethylaminoethyl methacrylate, etc.,and as fiber (b) any acrylic fiber dyeable with basic dye such as fibersof acrylonitrile copolymers containing such acidic comonomers asallylsulfonic acid, styrenesulfonic acid, itaconic acid, etc. Analternative combination may be one of,, as fiber (a), polyester orpolyamide fiber with, as fiber (b), an acrylic fiber. Numerous othercombinations are possible. Especially desirable are combinations whereinthe two fibers have dissimilar dyeing characteristics so that advantagemay be taken of a one-bath method for dyeing both fibers in differentcolors.

Once the fiber types have been blended and spun in accordance with thepresent invention, it is contemplated to ef-i fect coloration thereofaccording to usual techniques. Thus, the two fiber types may be dyedprior to spinning, one type of fiber may be dyed prior to spinning andthe other type or types dyed subsequent to spinning or fabrication, orfibers of dis similar dyeing properties may be employed in undyed statein I spinning, with dyeing being efi'ected after spinning or fabrica-.tion. 1 The invention is illustrated by the following examples in whichall parts and percentages are by weight.

EXAMPLES 1-2 Preparation of Fiber (a) 40 Staple acrylic fibers having adenier of 2.5, prepared from an acrylonitrile copolymer containing 91percent acrylonitrile, 8.8 percent methyl acrylate, and 0.2 percentallylsulfonic acid, are dyed as follows:

Dyebath: 0.1 percent O.W.F.

O.W.F. on weight ot'dry fiber.C. I. Basic Orange 2| 1.0 percent O.W.F.Levegal PAN retarder (Bayer, Germany) 1 2.0 percent O.W.F. acetic acid10.0 percent O.W.F. sodium sulfate Liquor/Fiber ratio: 20/1 The dyebathtemperature is increased from 70 to 100 C. at the rate of 0.5 C./minuteand maintained at 100 C. for 30 minutes.

Preparation of Fiber (b) Staple acrylic fibers of the same copolymerused immediate- 1y above but in lots of denier sizes 1.5, 2.5, 3.0, 4.0,6.0, and 10 are dyed in separate lots as follows:

Dyebath:

5 percent O.W.F. Sumiacryl Black FFP Cationic Dye (Sumitomo, Japan) 2percent O.W.F. acetic acid 5 percent O.W.F. sodium sulfate Liquor/Fiberratio: 20/1 The dyebath temperature is increased from 70 C. to 100 C. atthe rate of 1 C./minute and maintained at 100 C. for minutes.

Ynrn Preparation The various black fiber lots ofllber (b) are blendedwith the yellow-orange fiber (a) and spun into doubleply yarns having ayarn count of 32. Certain of the resulting yarns because of' fiberproportions or yarn deniers are outside the scope of the presentinvention and indicate comparative examples.

The various yarns spun above and the properties thereof are 0 El?! qyiri99 931- TABLE II.COLOR EFFECTS AND SPINNABILITY Although all of the spunyarns contain two colors, it can be seen that they differ considerablyfrom each other in color contrast. It can be readily seen that when thefiber used in minor amounts in these yarns is of a denier that is toolow, poor color contrasts are obtained. It can also be seen that whenthe fiber used in minor amounts in these yarns is ofa dejnier that istoo high, not only is color contrast poor but spinnability is also poor.

EXAMPLE 3 Preparation of Fiber (a) parts of undyed acrylic fibers of 3denier prepared from the same copolymer as in example 1 are employed. 36parts of the above (40 percent) are stretched by a Turbo-Stapler at adraft of 1.31 to have a shrinkage after boiling of 22 percent.

I Preparation of Fiber (b) 10 parts of staple acrylic fibers of 4.5denier prepared from a copolymer of 90 percent acrylonitrile, 7 percentmethyl acrylate, and 3 percent N,N-dimethylaminoethyl methacrylate, aredyed as follows:

Dyebath:

3 percent O.W.F. C. 1. Acid Red 167 3 percent O.W.F. sulfuric acid 10percent O.W.F. sodium sulfate Liquor/Fiber ratio: 20/1 The dyeing bathtemperature is increased from 70 C. to C. at the rate of 1 C./minute andmaintained at 100 C. for 60 minutes. Yarn Preparation Fiber (a) andfiber (b) in the proportions stated are spun into yarn. The yarn is thenprepared as a fabric by plain knitting. The resulting knitted fabric isthen dyed as follows:

Dyebath:

0.2 percent O.W.F. C. I. Basic Orange 21 2.0 percent O.W.F. acetic acid1.0 percent O.W.F. Levegal PAN Liquor/Fiber ratio: 20/1 The dyebathtemperature is increased from 70 C. to 100 C. at the rate of 0.5C./minute and maintained at 100 C. for

. 40 minutes.

The resulting dyed fabric has a highly contrasting twocolored patternwith red fibers appearing outstandingly brilliant against the sharporange-yellow background. Due to the shrinkage of the fiber stretched bythe Turbo-Stapler, the

knitted fabric has good bulk with the heavier fiber emerging onto thesurface so as to enhance further the color contrast.

EXAMPLE 4 Preparation of Fiber (a) 70 parts of a 3 denier acrylic fiberprepared from the same copolymer as in example 1 are employed in undyedstate.

Yarn Preparation A double-ply yarn of yarn count 20 is spun. The spunyarn is then dyed as follows:

Dyebath:

2 percent O.W.F. Maxilon Scarlet 2GL (J. R. Geigy, Switzerland) 0.8percent O.W.F. C. 1. Acid Yellow 29 3 percent O.W.F. acetic acid 1gram/liter Noigen ET 170 (Daiichi Kogyo Seiyaku) Liquor/Fiber ratio:50/1 The dyebath temperature is increased from 70 C. to 100 C. at therate of 05 CJminute and maintained at 100 C. for 45 minutes.

The dyed yarn is of red and y 110w color. The bright yellow of theheavier fiber stands out conspicuously, also rendering the red colorbrilliant. As a result, a sharp color contrast is obtained.

When the above procedure is followed in every detail except that thedenier of fiber (b) is 3, there is obtained a yarn showing a mereintenningling of red and yellow and a blurred color contrast.

EXAMPLE 5 Preparation of Fiber (a) 70 Parts of a 3 denier acryliccomposite fiber dyeable with basic dye and having a crimp number of22/inch are employed in undyed state. 1 Preparation of Fiber (b) 30Parts of a 6 denier acrylic fiber prepared from an acrylonitrilecopolymer composed of 90 percent acrylonitrile,

TABLE 111 YARNS OF GOOD SPINNABILITY AND COLOR CONTRAST Fiber (a) Fiber(b) Example Denier $2 Denier I:

6 1.5 60 2.5 40 7 1.5 50 3.5 50 8 1.5 80 3.0 20 9 2.0 60 3.0 40 10 2.050 5.5 50 l l 2.0 80 4.0 20 12 4.0 70 5.5 30 13 4.0 80 12.0 20 14 4.0 508.0 50 15 6.0 90 7.5 10 16 6.0 80 15.0 I7 6.0 70 12.0 30 18 8.0 90 10.0l0 19 8.0 50 18.0 50 20 8.0 60 16.0 40 2| 10.0 10 12.0 30 22 10.0 5020.0 50 23 12.5 80 14.5 20 24 12.5 90 23.0 10 25 15.0 60 17.0 40 26 15.070 25.0 30

7 percent methyl acrylate, and 3 percent N,N- dimethylaminoethylmethacrylate are employed in undyed state.

Yarn Preparation A double-ply yarn of yarn count 20 is spun. The spunyarn is then knitted into fabric. The fabric is then dyed following theprocedure of example 4.

The dyed fabric is comparable to the yarn of example 4 as to color andcolor contrast. The latent crimps of the composite fiber develop upondyeing thereby causing the heavier fiber to emerge on the surface of theyarn and producing a good bulk in the fabric. A pronounced colordifference and a welldefined color contrast are obtained.

EXAMPLE 6-26 Following the procedure of example 4 in every detail exceptfor the proportion sand deniers of fibers (a) and (b), a number of yarnsare prepared. In each instance yarns of good spinnability and excellentcolor contrast are produced. Table [11 below indicates the fiberproportions and deniers.

We claim:

1. Multicolored yarns comprising a blend of (a) from about 95 percent toabout 50 percent, by weight, of said blend, of a first fiber of onecolor, said first fiber having a denier d, and (b) correspondingly, fromabout 5 percent to about 50 percent, by weight, of said blend, of asecond fiber of a color different from that of said first fiber, saidsecond fiber having a denier D, said denier d being lower than saiddenier D and ranging from 1.5 to 15.0, with the denier D satisfying therelationship 0.87 log d+ 0.20 log D 1.39 log d+0.35, and

for 3.0 d150 0.87 log d+0.20 log 0; 0.57 log d-l-0.74.

2. Multicolored yarns of claim 1 wherein (a) is present to the extent of95 percent to percent, by weight of said blend, (b) is present to theextent of 5 percent to 15 percent by weight of said blend, and therelationship satisfied by said denier D is for 1.5 54:10.0

0.8710g d+ 0.20 1og D 1.01 log d+ 0.30, and

0.87 log d+0.20 210g D 0.57 log d+ 0.74.

3. Multicolored yarns of claim 2 wherein at least one of (a) and (b) isan acrylic fiber.

4. Multicolored yarns of claim 3 wherein said acrylic fiber is acomposite fiber.

5. Multicolored yarns of claim 3 wherein (b) is an acrylic fiber havinghigher shrinkage than (a).

6. Multicolored yarns of claim 2 wherein both (a) and (b) are acrylicfibers.

7. Multicolored yarns of claim 1 wherein at least one of (a) and (b) isan acrylic fiber.

8. Multicolored yarns of claim 7 wherein said acrylic fiber is acomposite fiber.

9. Multicolored yarns of claim 7 wherein (b) is an acrylic fiber havinghigher shrinkage than (a).

10. Multicolored yarns of claim 1 wherein both (a) and (b) are acrylicfibers.

2. Multicolored yarns of claim 1 wherein (a) is present to the extent of95 percent to 85 percent, by weight of said blend, (b) is present to theextent of 5 percent to 15 percent by weight of said blend, and therelationship satisfied by said denier D is for 1.5 d 10.0 0.87 log d +0.20 log D 1.01 log d + 0.30, and for 10.0 d 15.0 0.87 log d + 0.20 logD 0.57 log d + 0.74.
 3. Multicolored yarns of claim 2 wherein at leastone of (a) and (b) is an acrylic fiber.
 4. Multicolored yarns of claim 3wherein said acrylic fiber is a composite fiber.
 5. Multicolored yarnsof claim 3 wherein (b) is an acrylic fiber having higher shrinkage than(a).
 6. Multicolored yarns of claim 2 wherein both (a) and (b) areacrylic fibers.
 7. Multicolored yarns of claim 1 wherein at least one of(a) and (b) is an acrylic fiber.
 8. Multicolored yarns of claim 7wherein said acrylic fiber is a composite fiber.
 9. Multicolored yarnsof claim 7 wherein (b) is an acrylic fiber having higher shrinkage than(a).
 10. Multicolored yarns of claim 1 wherein both (a) and (b) areacrylic fibers.